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M/S DALMIA CEMENT (BHARAT) LTD

HEADER THICKNESS CALCULATION


1X120 TPH CFBC BOILER

Header & Piping Thickness Calculation


max Minimum
Outside Design Design Allowable Min. thick Ligament
Sl. Thickness No of working thickness % Margin Allowance
Description diameter Pressure Temp Material Stress available Efficiency
No (mm) headers temp required Available mm
(mm) (kg/cm^2) Deg. C (kg/m^2) (mm) (%)
deg.C (mm)

CONVECTION CAGE

FRONT/REAR ROOF
1 323.9 38.1 1 122 354 393 SA 106 Gr B 952.00 27.85 33.34 0.6500 19.70 5.49
HDR(CG)

2 Front Intermediate HDR(CG) 273 31.75 1 122 354 393 SA 106 Gr B 952.00 23.67 27.78 0.6500 17.36 4.11

3 Interconnecting HDR(CG) 168.3 21.95 4 122 354 393 SA 106 Gr.B 952.00 14.37 19.21 0.6500 33.69 4.84

4 FRONT BOTTOM HDR(CG) 273 31.75 1 122 354 393 SA 106 Gr.B 952.00 23.67 27.78 0.6500 17.36 4.11

REAR WALL BOTTOM


5 273 31.75 1 122 354 393 SA 106 Gr.B 952.00 23.67 27.78 0.6500 17.36 4.11
HDR(CG)

SIDE WALL(L&R)Bottom
6 219.1 28.58 2 122 354 393 SA 106 Gr.B 952.00 22.12 25.01 0.5500 13.07 2.89
HDR (CG)

SIDE WALL(L&R)TOP HDR


7 219.1 28.58 2 122 354 393 SA 106 Gr.B 952.00 18.47 25.01 0.6500 35.38 6.54
(CG)

SUPERHEATER 739.4

8 PSH outlet header 323.9 34.93 1.00 122 460.00 SA 335 P11 978.00 27.73 30.56 0.6500 10.23 2.84 0.83

9 wing wall I/L HDR 273 38.1 2.00 122 420.00 SA 335 P11 1019.00 27.53 33.34 0.5000 21.10 5.81 0.52

10 wing wall 0/L HDR 273 41.28 2.00 122 492.00 SA 335 P11 850.00 32.68 36.12 0.5000 10.54 3.44

11 SSH inlet header 323.9 31.75 1.00 122 465.00 SA 335 P11 973.00 22.09 27.78 0.8280 25.74 5.69

12 SSH outlet header 323.9 34.93 1.00 122 582.00 SA 335 P 91 830.00 25.51 30.56 0.8280 19.82 5.06
CROSS OVER DUCT

13 COD FRONT header 273 25.4 2.00 122 318 357 SA 106 Gr.B 1150.00 20.51 22.23 0.6500 8.38 1.72
14 COD REAR header 273 25.4 2.00 122 318 357 SA 106 Gr.B 1150.00 20.51 22.23 0.6500 8.38 1.72
15 COD SIDE header 273 28.58 4.00 122 318 357 SA 106 Gr.B 1150.00 23.80 25.01 0.5500 5.07 1.21 0.55

ECONOMISER

16 ECO inlet header 273.1 31.75 1.00 118 230 241 SA 106 Gr.B 1202.28 19.33 27.78 0.6030 43.71 8.45
17 ECO outlet header 219.1 20.62 2.00 118 276 287 SA 106 Gr.B 1202.28 12.39 18.04 0.8000 45.68 5.66
18 HANGER OUTLET HDR 219.1 20.62 2.00 118 289 300 SA 106 Gr B 1202.28 12.39 18.04 0.8000 45.68 5.66

PREPARED BY: APPROVED BY:


JRY JRK
M/S DALMIA CEMENT (BHARAT) LTD
HEADER THICKNESS CALCULATION
1X120 TPH CFBC BOILER

BOILER FEED PUMP


36 feed water suction hdr 457.2 11.13 1 6.5 160 160 SA 106 Gr B 1202.2 2.00 9.74 0.95 386.15 7.74

37 feed water discharge hdr 323.9 28.58 1 155 160 160 SA 106 Gr B 1202.2 20.18 25.01 0.95 23.92 4.83
38 Feed water header 323.9 33.32 1 155 210 210 SA 106 Gr B 1202 23.31 29.16 0.8 25.06
39 Auxiliary steam header 323.9 10.31 1 6 250 250 SA 106 Gr B 1202 1.85 9.02 0.7 388.37
40 Auxiliary steam header 114.3 8.56 1 21 300 300 SA 106 Gr B 1202 1.99 7.49 0.7 276.37

PREPARED BY: APPROVED BY:


JRY JRK
M/S DALMIA CEMENT LTD
HEADER SIZING CALCULATION
1X120 TPH CFBC BOILER

Header Sizing
Sl. Description Outside Header Inside Fluid flow Operating Operating Specific Actual Velocity Velocity
No. dia thk. dia (kg/hr) pressure temp. volume velocity m/s/mmID m/s/mmID
( mm) (mm) m (ksc(a)) (deg. C) (m3/kg) (m/s) (max limit)

CONVECTION CAGE
FRONT/REAR ROOF 0.24770 133900 107.5 354 #NAME? #NAME? #NAME? 0.1200
1 HDR(CG) 323.9 38.1 #NAME? #NAME?
0.21 133900 107.5 354 #NAME? #NAME? #NAME? 0.1200
Front Intermediate
2 HDR(CG) 273 31.75 #NAME? #NAME?
0.12 33475 107.5 354 #NAME? #NAME? #NAME? 0.1200
3 Interconnecting HDR(CG) 168.3 21.95 #NAME? #NAME?
FRONT BOTTOM 0.21 133900 107.5 354 #NAME? #NAME? #NAME? 0.1200
4 HDR(CG) 273 31.75 #NAME? #NAME?
REAR WALL BOTTOM 0.21 133900 107.5 354 #NAME? #NAME? #NAME? 0.1200
5 HDR(CG) 273 31.75 #NAME? #NAME?
0.16 66950 107.5 354 #NAME? #NAME? #NAME? 0.1500
SIDE WALL(L&R)Bottom
6 HDR (CG) 219.1 28.58 #NAME? #NAME?
SIDE WALL(L&R)TOP 0.16 66950 107.5 354 #NAME? #NAME? #NAME? 0.1200
7 HDR (CG) 219.1 28.58 #NAME? #NAME?

SUPERHEATER
0.25 140000 105 421.00 #NAME? #NAME? #NAME? 0.1200
8 PSH outlet header 323.9 34.93 #NAME? 30.48 #NAME?
0.2 70000 103.5 395.00 #NAME? #NAME? #NAME? 0.1500
9 wing wall I/L HDR 273 38.1 #NAME?
0.19 70000 100.00 454.00 #NAME? #NAME? #NAME? 0.1200
10 wing wall 0/L HDR 273 41.28 #NAME?
0.26 140000 99.00 440.00 #NAME? #NAME? #NAME? 0.1500
11 SSH inlet header 323.9 31.75 #NAME?
0.25 140000 96.00 545 #NAME? #NAME? #NAME? 0.1200
12 SSH outlet header 323.9 34.93 0.0000

PREPARED BY : APRROVED BY:


JRA JRK
M/S DALMIA CEMENT LTD
HEADER SIZING CALCULATION
1X120 TPH CFBC BOILER

CROSS OVER DUCT


0.22 70000 111 318 #NAME? #NAME? #NAME? 0.1200
13 COD FRONT header 273 25.4
0.22 70000 111 318 #NAME? #NAME? #NAME? 0.1200
14 COD REAR header 273 25.4
0.22 70000 111 318 #NAME? #NAME? #NAME? 0.1200
15 COD SIDE header 273 25.4
ECONOMISER
0.21 #NAME? #NAME? #NAME? 2m/s
16 ECO inlet header 273.1 31.75 140000 116 230 128
0.18 #NAME? #NAME? #NAME? 2m/s
17 ECO outlet header 219.1 20.62 70000 116 276
0.18 #NAME? #NAME? #NAME? 2m/s
18 HANGER OUTLET HDR 219.1 20.62 70000 116 289 115.1

PREPARED BY : APRROVED BY:


JRA JRK
M/S DALMIA CEMENT LTD
HEADER SIZING CALCULATION
1X120 TPH CFBC BOILER

BOILER FEED PUMP


0.43 #NAME? #NAME? #NAME? 0.6-0.9
36 feed water suction hdr 457.2 11.13 280000 6.5 160
0.27 #NAME? #NAME? #NAME? 1.5-2.4
37 feed water discharge hdr 323.9 28.58 280000 162 160
38 Feed water header 323.9 33.32 0.26 280000 162 230 #NAME? #NAME? #NAME? 1.5-2.4
39 Auxiliary steam header 323.9 10.31 0.3 15000 6 250 #NAME? #NAME? #NAME? 1.5-2.6
Auxiliary steam header 114.3 8.56 0.1 3000 21 300 #NAME? #NAME? #NAME? 1.5-2.7
Auxiliary steam header
0
0
0
0
0
0
0
0
0

PREPARED BY : APRROVED BY:


JRA JRK
M/S BALASORE ALLOYS LTD
HEADER THICKNESS CALCULATION
2 X 140 TPH CFBC BOILER

Piping Thickness Calculation


Minimum
Outside No of Design Design Allowable Min. thick
Thickness thickness % Margin
Sl.No Description diameter headers Pressure Temp Material Stress available
(mm) required Available
(mm) per boiler (kg/cm^2) Deg. C (kg/m^2) (mm) Allowance
(mm)
mm
406.4 9.53 1 6.4 160
1 Feed water piping from deaerator to
BFP suction SA 106 Gr B 1202.00 1.83 8.34 355.90
273 9.27 1 6.4 160
Feed water piping from BFP header
2 to BFP SA 106 Gr B 1202.00 1.47 8.11 449.97 6.64
219.1 20.62 1 160 160
3 Feed water piping from BFP to BFP
header SA 106 Gr B 1202.00 14.42 18.04 25.10
273.1 25.4 1 160 160
Feed water piping from BFP outlet to
4 HP heater-I SA 106 Gr B 1202.00 17.79 22.23 24.91
Feed water piping from HP heater-I to 219.1 15.09 1 160 160
5
economiser SA 106 Gr B 1202.00 14.42 13.20 -8.45 -1.22
42.2 4.85 1 160 160
6 Spray Piping to boiler attemperator-1 SA 106 Gr B 1202.00 3.38 4.24 25.43
114.3 13.49 1 96 540
7
steam line from CSDH to PRDS - 1 SA 335 P 22 520.50 10.40 11.80 13.49 1.40
steam line from PRDS-1 to 355.6 9.53 1 7.00 250
8 ejector/gland sealing SA 106 Gr B 1202.00 1.78 8.34 367.83
219.1 15.09 1 117.00 277
9
Feed water piping from eco to drum SA 106 Gr.B 1202.00 10.92 13.20 20.93 2.29
219.1 15.09 1 122 318
10 Drum to COD SA 106 Gr.B 1202.00 11.33 13.20 16.52 1.87
11 219.1 15.09 1 122 325
COD to cage SA 106 Gr.B 1202.00 11.33 13.20 16.52 1.87
273 21.44 1 122 421
12 PSH to DSH-1 SA 355 P11 1018.00 16.18 18.76 15.92 2.58
13 273 21.44 1 122 395
DSH-1 to WWSH SH SA 355 P11 1043.00 15.83 18.76 18.48 2.93
323.9 25.4 1 122 454
14 WWSH to Final SH SA 355 P11 984.00 19.66 22.23 13.06 2.57
323.9 25.4 1 122 555
18 Main steam pipe upto MSSV SA 355 P91 1045.00 18.61 22.23 19.40 3.61
406.4 50.8 1 105.5 540
Main steam from MSSV to CSDH SA 355 P22 520.50 38.15 44.45 16.52
558.8 88.9 1 105.5 540
CSDH SA 355 P22 520.50 71.42 77.79 8.91
M/S BALASORE ALLOYS LTD
HEADER THICKNESS CALCULATION
2 X 140 TPH CFBC BOILER

60.3 8.74 1 97 540


19
Steam piping from CSDH to PRDS-II SA 355 P22 520.50 5.89 7.65 29.84
Steam piping from PRDS-II to termial 114.3 6.08 1 21 250
20 point SA106 Gr B 1202.00 1.74 5.32 205.78
60.3 8.74 1 66 490
21
SA 355 P11 871.70 2.95 7.65 159.28
114.3 6.02 1 20 320
22 SA 106 Gr B 1202.00 1.69 5.27 211.12
323.9 21.44 1 66 490
23 SA 335 P11 871.70 12.56 18.76 49.31
24 406.4 9.53 1 10 180 SA 106 Gr B 1202.00 2.43 8.34 242.66
steam line from turbine nozzle bleed 219.1 8.18 1 20 320
25 to HP heater SA 106 Gr B 1202.00 2.56 7.16 179.84
steam line from turbine bleed to 406.4 9.53 1 4 200
26 deaerator SA 106 Gr B 1202.00 1.43 8.34 485.14
27 355.6 9.53 1 2.3 125 SA 106 Gr B 1202.00 1.09 8.34 665.10
28 114.3 8.56 1 9 400 SA 106 Gr B 908.00 1.31 7.49 470.16
29 114.3 8.56 1 9 400 SA 106 Gr B 908.00 1.31 7.49 470.16
30 33.4 3.38 1 2 100 SA 106 Gr B 1202.00 0.78 2.96 280.26
31 114.3 8.56 1 2 72 SA 106 Gr B 1202.00 0.85 7.49 786.38
32 114.3 8.56 1 5 125 SA 106 Gr B 1202.00 0.99 7.49 658.68
33 114.3 8.56 1 9 400 SA 106 Gr B 908.00 1.31 7.49 470.16
34 HP heater normal drain to deaerator 168.3 10.97 1 18 170 SA 106 Gr B 1202.00 2.00 9.60 379.75
168.3 10.97 1 18 170
35 HP heater emergency drain to hotwell SA 106 Gr B 1202.00 2.00 9.60 379.75
36 HP heater vent to deaerator 60.3 3.91 1 9 400 SA 106 Gr B 908.00 1.05 3.42 226.65
steam inter connection from CSDH to 323.9 31.75 1 89 490
37 existing CSDH SA 335 P 11 871.70 16.48 27.78 68.56
Feed water interconnection to existing 219.1 18.26 1 130 160
38 feed water line SA 106 Gr B 1202.00 11.99 15.98 33.25
39 219.1 18.26 1 9 400 SA 106 Gr B 219.85 15.98 -92.73
40 114.3 8.56 1 9 400 SA 106 Gr B 115.05 7.49 -93.49
41 114.3 8.56 1 9 400 SA 106 Gr B 115.05 7.49 -93.49
Piping Sizing
Allowable
Outside Pipe Fluid Operating Operating Specific Actual Allowable
No of Velocity
Sl. No. Description dia thk. flow pressure temp. volume velocity Velocity
Lines m/s(AS PER
( mm) (mm) (kg/hr) ksc(a) (deg. C) (m3/kg) (m/s) m/s
Tender)

Feed water piping from


1 406.4 9.53 1 280000 6.4 160 #NAME? #NAME? 0.6-0.9 0.6-0.9 0.6-0.9
deaerator to BFP suction

Feed water piping from BFP


2 273 9.27 1 140000 6.4 160 #NAME? #NAME? 0.6-0.9 1.8-2.4 1.8-2.4
header to BFP

Feed water piping from BFP to


3 219.1 20.62 1 140000 160 160 #NAME? #NAME? 1.5-2.4 1.8-2.4
BFP header
Feed water piping from BFP
4 273.1 25.4 1 280000 160 160 #NAME? #NAME? 1.5-2.4 1.8-2.4
outlet to HP heater-I
Feed water piping from HP
5 219.1 15.09 1 140000 160 160 #NAME? #NAME? 3.00
heater-I to economiser
Spray Piping to boiler
6 42.2 4.85 1 7000 160 160 #NAME? #NAME? 3.00
attemperator-1
steam line from CSDH to
7 114.3 13.49 1 15000 96 540 #NAME? #NAME? 35-50
PRDS - 1
steam line from PRDS-1 to
8 355.6 9.53 1 15000 6.00 250 #NAME? #NAME? 28-43
ejector/gland sealing
Feed water piping from eco to
9 219.1 15.09 1 140000 116.00 277 #NAME? #NAME? 2-3
drum
10 Drum to COD 219.1 15.09 1 70000 111.5 318 0.01737 12.1 30-50 20-35 30-50 >200mm
20-35 50 to 150mm
11 COD to cage 219.1 15.09 1 70000 109.5 325 #NAME? #NAME? 50.00 20-35 15-25 <50mm

12 PSH to DSH-1 273 21.44 1 140000 105 421 #NAME? #NAME? 50.00 35-61

13 DSH-1 to WWSH SH 273 21.44 1 140000 104.5 395 #NAME? #NAME? 50.00 50-76

14 WWSH to Final SH 323.9 25.4 1 140000 100 454 #NAME? #NAME? 50.00 50-76
50-76 >200mm
18 Main steam pipe upto MSSV 323.9 25.4 1 140000 97 540.00 #NAME? #NAME? 50 50-76 35-61 50 to 150mm 0.18
22-35
Main steam from MSSV to <50mm
0 406.4 50.8 1 280000 97 540.00 #NAME? #NAME? 50 50-77
CSDH
0 CSDH 558.8 88.9 1 280000 97 540.00 #NAME? #NAME? 50 50-78 #NAME?

M/s DALMIA CEMENT (BHARAT) LTD.


<50mm

Steam piping from CSDH to


19 60.3 8.74 1 3000 96 540 #NAME? #NAME? 35-50 35-61
PRDS-II
Steam piping from PRDS-II to
20 114.3 6.08 1 3000 21 250 #NAME? #NAME? 50 20-30 25-40 30-50
termial point
21 0 60.3 8.74 1 1000 66 485 #NAME? #NAME? 22-35 22-35

22 0 114.3 6.02 1 6000 20 320 #NAME? #NAME? 28-43 20-33 28-43 35-55

23 0 323.9 21.44 1 100000 66 490 #NAME? #NAME? 50


24 0 406.4 9.53 1 100000 10 180 #NAME? #NAME? 35-50
steam line from turbine nozzle
25 219.1 8.18 1 26000 20 320 #NAME? #NAME? 35-50
bleed to HP heater
steam line from turbine bleed to
26 406.4 9.53 1 30000 4 200 #NAME? #NAME? 35-50
deaerator
27 0 355.6 9.53 1 100000 2.3 125 #NAME? #NAME? 25-43
28 0 114.3 8.56 1 100000 9 400 #NAME? #NAME?
29 0 114.3 8.56 1 100000 9 400 #NAME? #NAME?
30 0 33.4 3.38 1 100000 2 100 #NAME? #NAME?
31 0 114.3 8.56 1 100000 2 72 #NAME? #NAME?
32 0 114.3 8.56 1 100000 5 125 #NAME? #NAME?
33 0 114.3 8.56 1 100000 9 400 #NAME? #NAME? 28-54
HP heater normal drain to
34 168.3 10.97 1 100000 18 170 #NAME? #NAME?
deaerator
HP heater emergency drain to
35 168.3 10.97 1 100000 18 170 #NAME? #NAME?
hotwell
36 HP heater vent to deaerator 60.3 3.91 1 100000 9 400 #NAME? #NAME? 28-57
steam inter connection from
37 323.9 31.75 1 100000 89 520 #NAME? #NAME? 50
CSDH to existing CSDH
Feed water interconnection to
38 219.1 18.26 1 100000 130 160 #NAME? #NAME? 1.5-2.4
existing feed water line
39 0 114.3 8.56 1 100000 9 400 #NAME? #NAME? 28-60
40 0 114.3 8.56 1 100000 9 400 #NAME? #NAME? 28-61
41 0 114.3 8.56 1 100000 9 400 #NAME? #NAME? 28-62

138.78

135.7 127

M/s DALMIA CEMENT (BHARAT) LTD.

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